1/32 Endmill cutting aluminum?

[DennisCNC]

I need to make a aluminum gear 1 1/2 diameter with 34 teeth. I found some 1/32 end mills on ebay, 2 and 4 flute. Wich will be better for this? This will but the BP retro to a real test.

Endmill

[Ken_Shea]

Dennis,
That small the two flute would be best and as fast (RPM) as that BP will go

Carbide is the way to go.

Ken

[DennisCNC]

What if I tape a dremel to the quill

What feed rate and depth of cut will I need to use?

[JFettig]

Runnout, You'll typically find .01" runout in a dremel tool. My RTX had less but not much. we had to drill some .004" holes and we tried but it kept breaking the drills and only successfully drilled 1 hole.


Jon

[Cold Fusion]

2 flute for sure. The 4 flute wouldn't have enough clearence for the chips. I cut my gears with a 2 flute 1/32" endmill at 3500rpm with a .02 DOC at 2.5ipm.

[dannyboysd89]

You should maybe look into WM Berg for a gear like this and then just mill it to size (unless this is a very irregular gear). I am doing this for a project I have and spent $20 on a gear and will just skin the 2 faces and be done.

Dan